Cutting Torch Tip Size Chart: Victor and Harris by Thickness

The right cutting torch tip size for the job depends on material thickness. A tip that’s too small for the thickness can’t provide enough cutting oxygen to sustain the cut. A tip that’s too large wastes gas, produces a wider kerf, and gives a rougher edge on thin material. The charts below cover the two most common tip systems, Victor and Harris, with oxygen and acetylene pressure settings for each size.

As a quick rule, the tip number roughly matches the maximum thickness in fractions of an inch. A #1 tip handles up to about 1" thick. A #2 handles up to about 2". There are exceptions at the small end (the 000, 00, and 0 sizes cover sheet metal to 3/8"), but the pattern holds for general use.

Victor Cutting Tip Chart (1-Piece, 101 Series)

Victor’s numbering system uses a three-part designation: the first number is the tip size, the second is the gas type (1 = acetylene), and the series number. For acetylene cutting on a Victor torch, the common series is 101 (standard) and 3-101 (high-speed).

Harris Cutting Tip Chart (6290 Series)

Harris uses a simpler numbering system. Each number corresponds directly to a thickness range. The 6290 series is Harris’s standard acetylene cutting tip.

How to Read the Charts

Thickness range: The range of material thickness the tip handles comfortably. For best results, use the tip whose range includes your material in the middle, not at the extreme.

Oxygen PSI: Working pressure at the regulator for the cutting oxygen stream. This is the pressure that feeds the cutting lever. Higher pressure for thicker material.

Acetylene PSI: Working pressure for the preheat flame. Stays relatively constant (5-8 PSI) across most tip sizes. Never exceed 15 PSI on acetylene.

Cut speed: Approximate inches per minute for a clean cut on clean steel. Actual speed varies with steel condition, plate temperature, and operator skill.

Kerf width: The width of the cut slot. Increases with tip size because the cutting oxygen orifice is larger.

Pressure Setting Procedure

1. Close both torch valves (acetylene and oxygen on the torch handle)
2. Open the acetylene cylinder valve 1/4 to 1/2 turn
3. Set acetylene regulator to the chart pressure for your tip
4. Open the oxygen cylinder valve fully (all the way open, per standard practice)
5. Set oxygen regulator to the chart cutting pressure for your tip
6. Light the torch with the acetylene valve and adjust
7. Open the oxygen valve on the torch and adjust to neutral flame
8. Test the cutting oxygen by pressing the lever. Pressure should remain steady at the regulator. If it drops more than 5 PSI, increase the setting slightly.

Some operators set a slightly higher oxygen pressure than the chart indicates, then dial it back during actual cutting based on results. The charts are starting points.

For a complete step-by-step regulator setup and shutdown procedure, see oxy-fuel regulator setup.

Matching Tip to Application

Sheet Metal (Up to 1/8")

Use the smallest tip available (000 or 00). The small orifice produces a narrow kerf and minimal heat input. Travel speed is fast. Keep the preheat cones just above the surface (1/16" or less). These small tips are easily clogged, so keep tip cleaners handy.

Light Plate (1/8" to 3/8")

The most common range for shop cutting. A #0 tip handles this range well on both Victor and Harris systems. This is where oxy-fuel cutting is at its cleanest and most controllable. Preheating takes 5-10 seconds at the edge.

Medium Plate (3/8" to 1")

Step up to #1 on both systems. Preheat takes 10-20 seconds depending on how quickly you want to start. Higher oxygen pressure (30-40 PSI) provides the volume needed to blow through the thicker material. At 1", you’re at the top of the #1 tip’s range. If cuts are slow or incomplete, move to #2.

Heavy Plate (1" to 3")

Tips #2 and #3 handle the heavy plate range. Preheat takes 20-40 seconds. Oxygen consumption increases significantly at these thicknesses. A 251 CF oxygen cylinder lasts much shorter on heavy cutting. Plan your gas supply accordingly. See oxy-acetylene tank sizes for consumption estimates.

Extra Heavy Plate (3" to 6")

Tips #4 and #5 for the heaviest shop work. These tips require the highest oxygen pressure (50-65 PSI) and consume gas rapidly. Preheat time is 30-60+ seconds. Cut speed drops to 4-6 IPM. These cuts are rare in small shops but common in heavy industry, ship breaking, and demolition.

Tip Maintenance

Cleaning

Cutting tips clog over time from slag splash, soot, and oxidation of the copper surfaces. Clean regularly with tip cleaners (small wire files sized to the tip orifices):

• Insert the tip cleaner into each preheat hole and the center cutting hole
• Push straight in and out gently, don’t ream or enlarge the holes
• Never use drill bits (they enlarge the orifice permanently)
• Clean after every cutting session and whenever cut quality degrades

When to Replace

Replace the cutting tip when:

• Orifices are visibly enlarged or oblong (uneven flame pattern)
• The tip seat is pitted or damaged (causes gas leaks)
• The tip face is deeply gouged from contact with slag
• Clean-cut quality can’t be achieved despite correct pressure settings

A good cutting tip lasts hundreds of hours with proper care. Tips are inexpensive ($5-15 each), so replace them before they degrade your cut quality.

Tip Seat Maintenance

The tip seats into the torch head with a metal-to-metal seal. Damaged or dirty seats cause gas leaks, which produce uneven flames and inconsistent cutting. Clean the seat area on both the tip and the torch head with a clean cloth. If the seat is scratched or pitted, replace the tip.

Common Tip-Related Problems

Flame is uneven or lopsided: One or more preheat orifices are clogged. Clean with tip cleaner. If the cutting oxygen stream is off-center, the center orifice is damaged. Replace the tip.

Cutting oxygen pressure drops when lever is pressed: Tip is too small for the thickness (can’t flow enough oxygen). Step up to the next tip size. Also check that the oxygen regulator is set high enough and that the cylinder pressure is adequate.

Excessive slag on the cut face: Tip is too large (too much preheat, not enough precision), oxygen pressure too low, or travel speed too slow. Try a smaller tip if you’re at the thin end of the current tip’s range.

Preheat flame keeps going out: Gas pressure too low, tip orifices clogged, or a gas leak at the tip seat. Check pressures, clean the tip, and inspect the seat.

For a full rundown of cutting problems and solutions, see oxy-acetylene cutting guide.

One-Piece vs Two-Piece Tips

Cutting tips come in two designs:

One-piece tips (Victor 101 series, Harris 6290 series): The preheat orifices and cutting orifice are drilled into a single copper piece. Simpler, cheaper, and easier to clean. Adequate for most shop cutting. When the tip wears out, replace the whole unit.

Two-piece tips (seated): A separate inner piece contains the cutting orifice, seated inside an outer shell with the preheat orifices. Found on heavy-duty industrial torches. The inner piece can be replaced independently. Better for very heavy cutting where the cutting orifice wears faster than the preheat ring.

For most shop applications, one-piece tips are standard and widely available. Two-piece tips are found on Victor Journeyman and other heavy-duty torch handles.

Tip-to-Torch Compatibility

Cutting tips are not universal. Each torch manufacturer uses a proprietary seat design:

• Victor: Victor tips fit Victor torch handles. The seat is a tapered cone.
• Harris: Harris tips fit Harris torch handles. Different taper geometry than Victor.
• Smith: Smith tips fit Smith handles.

Some aftermarket brands make tips that fit multiple torch types, but fitment can vary. A poor seat allows gas leaks between the preheat and cutting circuits, producing a mixed flame with poor cutting performance. Stick with tips matched to your torch brand for reliable operation.

Gas Consumption Rates by Tip Size

Planning your gas supply around tip size prevents mid-job cylinder changes. Here are approximate oxygen consumption rates for cutting (the biggest gas consumer):

Total oxygen consumption is the cutting oxygen plus the preheat oxygen. A #1 tip on 1/2" steel uses roughly 80-110 CFH total oxygen. A 251 CF cylinder lasts about 2-3 hours of actual cutting at this rate. For cylinder capacity planning, see oxy-acetylene tank sizes.